My approach to repairing the left hand side was somewhat different to the right hand side. It soon became evident that the RHS had recieved extensive damage which seemed to have been repaired with injuditious use of a sledgehammer and stick welder that meant fitting new panels was difficult as they would not line up. The plan therefore was cut out great swathes of the inner panels and replace with complete sections - taking measurements from the LHS.
This side appeared in much better fettle with just rust degredation (especially on sills and floors) without the structoral inaccuracies evident on the other side. Therefore, the approach here was to cut just the rusty parts of panels and replace with repair panels, whereby the structoral integrity is not disturbed so dimensions remain intact.
A little bit of repair work was required on the chassis but this was just a case of cutting out rusted sections and welding in 2mm plate repair sections. The front outrigger was totally shot, so was replaced, but the rear one was still structurally sound so was rust treated and left in tack.
The inner and outer sill was very carefully cut out in pieces without disturbing (where possible) other panels that attach to it. This made the job of refitting the new sill much easier as it aligned nicely with the front inner wing, front footwell, A pillar, B pillar and rear inner wing.
The floor panels were completely shot from footwell to rear kick board. Repair panels for the front footwell and sidewalls were fabricated from sheet steel and welded in. New complete centre and rear floor panels were purchased and welded in place. The lower half of the B pillar face plate and inner wing was made up and cut in.
Finally a new outer sill and transmission tunnel were welded in place and the job's a good 'un.
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